Metso GasificationIEA Task 33 meeting
2011-10-19 Piteå SwedenTimo Honkola
Chief EngineerGasification Technology
Metso Global supplier of sustainable technology and services
• Our customers operate inOur customers operate inthe following industries:
- Mining- ConstructionConstruction- Energy- Oil and gas- Recycling- Pulp and paper
• About 28,500 employeesin over 50 countriesin over 50 countries
• Net sales in 2010EUR 5.6 billion
• Shares listed on NASDAQ OMX Helsinki Ltd
© Metso2
Metso Power Wide scope of fuel-flexible power technology
Heating plants Automation systemsGasificationBoiler plants Modular power plants
Power solutions
Recovery boilers Automation Rebuilds and upgradesEnvironmental systems
Profilers Intelligent control valves ESD valves
Recovery boilers Automation Rebuilds and upgradesEnvironmental systems
Automation systems
© Metso3
Metso’s evolution in gasification
TAMPELLA POWER GÖTAVERKEN
Tampere pilot plant •15 MWth pressurized FB gasifier• Biomass and coal gasification development
Atmospheric CFB gasification development• Värö lime kiln gasifier 1987
ENVIROPOWER
• Hot gas cleaning development
METSO CFB /BFB
First generation
ENVIROPOWER Boiler experience
METSO
CFB GASIFIER
NEW DEVELOPMENT ACTIVITY• Fuel drying technology• Gas cleaning • Biomass gasification for limekilns CFB GASIFIERBiomass gasification for limekilns• Biomass gasification for power production • Waste gasification
Second generation
© Metso IEA Task 33 Meeting in Piteå 19.10.20114
Gasification technologiesPosition of Metso CFB gasification
PRESSURE OXIDISIER PROCESS ASH FUEL SIZE APPLICATIONPRESSURE OXIDISIER PROCESS ASH FUEL SIZE APPLICATION
Atmospheric Air Fixed bed Slagging CoalSMALL0 – 10 MW
Combustionengines
Pressurized Oxygen BFB Non-slagging BiofuelMEDIUM
5-50 MW
Combustible gas for industrial
furnaces
F il f l
Steam CFB OilLARGE50 -200
MW
Fossil fuel replacement by
bio/waste in power plants
Entrained flow Gas
HUGE 200 -2000
MWIGCC
TransportTransport reactor Waste Transport fuels
Flame gasification Synthetic NG
© Metso Metso International Bioenergy Seminar Juhani Isaksson
5
Metso’s CFB gasifier
CFB GasifierCFB Gasifier
Size 20 – 140 (200) MWthMWth
Fuel Biomass, waste
Gasification media Air (steam)
Operating 750 – 900 COperating temperature
750 900 C
Operating pressure
5-30 kPa(g) /0 05-0 3 atm(g)pressure /0,05-0,3 atm(g)
Product gas heating value
3-7 MJ/kg (LHV)
© Metso Metso International Bioenergy Seminar Juhani Isaksson6
Metso’s Solution for Gasification CFB Gasifier
Product gas for Product gas for Product gas fromProduct gas for (lime) kilns
• Sawdust, forest
Product gas for power boilers
• Woody biomass, bark,
Product gas from waste for power
production
• Waste derived fuel,residues, fresh wood,
bark • 20 – 80 MWfuel units • Typically includes a
dryer
y , ,peat, straw…
• Superior electricity efficiency
• (Existing) power boilers
• Waste-derived fuel • High electricity
efficiency • Typically a new gas
boiler G fdryer
• Dusty product gas • Also other types of
kilns possible
boilers • 50 – 150 MWfuel units • Typically includes a
dryer • (Gas filtering)
• Gas filtering -> clean product gas
• 50 – 100 MWfuel units or multiple units
connected to a boiler
© Metso7
Metso’s Solution for Gasification CFB gasification: Reaction temperature
2500
2000
DRY FUEL
WET FUEL
1500
re (C
)
WET FUEL
CFB gasification-Operational area
1000
Tem
pera
tur
500
T
00,1 1 10
GASIFICATION COMBUSTION
© Metso8
0,1 1 10Air coefficient
Fuel moisture vs. gasifier output
Fuel moisture 20%(Design
30% 40%
point)Gasifier max output % 100 89 77
Example case:Waste fuel, HHV dry 22,5 MJ/kg, Ash 7,6%
Gas heat value MJ/m3n hot ( incl. sensible heat )
5
6
7
8
t MJ/
m3 n
( )
2
3
4
5
s he
at v
alue
hot
0
1
20 40
Gas
Fuel moisture
© Metso Metso International Bioenergy Seminar Juhani Isaksson9
Biomass gasifier for a lime kiln
• A lime kiln can easily be switched yover to use gasified biomass
• The size is usually large enough to make solution economically viablemake solution economically viable
• Fuel is normally available in a mill • During the second oil crisis in the
1980s, several gasifiers were built to replace oil with biomass
• At Värö, Södra Cell, Sweden, aAt Värö, Södra Cell, Sweden, a Metso (Götaverken) gasifier has been used since 1987
=> Over 20 years of industrial=> Over 20 years of industrial experience
© Metso Metso International Bioenergy Seminar Juhani Isaksson
10
Typical gasification applicationsExample:100 MW of biofuel available at the district
• Cofiring is an efficient way to use biomassCofiring is an efficient way to use biomass
Small boiler100 MW, fuel Small boilerefficiency 25 %
25 MW green electricity
100 MW, fuel Large boilerefficiency 40 %
40 MW green electricity+ 160 MW coal electricity400 MW coal
The final outcome is 60 % more green electricity !
© Metso Metso International Bioenergy Seminar Juhani Isaksson11
Biomass gasification into the existing coal-fired plant
Short delivery time and minimized production interference
Relatively low investmentinvestment cost
Integrated drying process Original coal capacity available
© Metso Metso International Bioenergy Seminar Juhani Isaksson12
Vaskiluoto coal-fired power plant in Vaasa
• In operation since 1982 p• Production
- electricity 230 MW- district heating 170 MW
• Coal consumption400,000 – 500,000 t/a, ,
• Produces approximately 90% of the district heat needs in Vaasa regionregion
© Metso Metso International Bioenergy Seminar Juhani Isaksson13
Vaskiluodon Voima Oy gasification projectEnables to replace a large share of coal with biomass
• 140 MW biomass gasifier and dryer• Adjoined to the existing
560 MW coal-fired power plant• Up to 40 percent replacement of coal
Schedule• Contract signed June 2011Contract signed June 2011• Plant operational 12/2012
Total project cost < 40 M€
© Metso Metso International Bioenergy Seminar Juhani Isaksson14
Vaskiluodon Voima biomass gasification plant
Instrumentation,
Product gas
electrification and automation
Dried biomass
Wet biomass
Existing PC boilerBiomass receiving Large-scale belt dryer CFB gasifier Existing PC boiler modifications and new
burners
Biomass receivingand pre-handling
Large scale belt dryer CFB gasifier 140 MWfuel
© Metso Metso International Bioenergy Seminar Juhani Isaksson15
Vaskiluodon Voima, FinlandCONFIDENTIAL
External Fuel HandlingStart-up 2012
Gasifier
DryingProcess Gasification (140 MW) for
Power Generation
Fuels Forest resudues (chips),
Storage Silos
Fuels Peat
Fuel Receiving 4 x 120 m3
Receiving and
Sampling
Receiving and ScreeningCapacity
600 m3/h
Fuel AutomaticScreening
Receiving
Sampling 5 samples / truck
Fuel Silosand Reclaiming
2 x 2 500 m3
2 x 50 - 200 m3/hReclaimingCapacity
2 x 50 200 m /h
DryingCapacity
10 t/hof evaporated water
© Metso Metso International Bioenergy Seminar Ari Havu16
Metso belt dryer for biomassCONFIDENTIAL
Double layerSEMI-DRY
PRODUCT INHEAT
AIR IN
WETPRODUCT
IN
DRY PRODUCT
HEATEXCHANGER
FEEDINGSCREW
DRY PRODUCTDISCHARGE SCREW
DRYPRODUCT
OUTFAN
BELTWASHING
AIR OUT
SEMI_DRY PRODUCTDISCHARGE SCREWFor water evaporation
AIR OUTcapacity up to
20 tons/h
© Metso Metso International Bioenergy Seminar Ari Havu17
Lahti Energia - solid waste gasification
• 160 (2x80) MW 250 000 tn/a160 (2x80) MW, 250 000 tn/a• Total Investment 157 M€• Start up April 2012 Waste fuel handling
Gas boilerand APC
1. Fuel handling 2. Gasifier3 Gas cooling3. Gas cooling 4. Gas filter 5. Gas boiler and
flue gas cleaning
Old PC boilerGasifier
1
2. 3.
4.
5.
boilerand gas cooler1.
© Metso IEA Task 33 Meeting in Piteå 19.10.201118
Technical conceptp
• Gasify waste at 850-900 C 1,E-03Gasify waste at 850-900 C• Cool it down to about 400 C
- all corrosive components, alkalichlorides, Pb Zn will be in solid form
1,E-05
1,E-04
AC/GAS/NaCl -AC/GAS/KCl -AC/GAS/ZnCl2 -AC/GAS/PbCl2 -Saturated steam-Na2SO4(g)Saturated steam-K2SO4(g)Pb, Zn will be in solid form
• Filter all dust out so the resulting gas is clean
1,E-08
1,E-07
1,E-06
log
p Saturated steam-ZnCl2(g)Saturated steam-PbCl2(g)Saturated steam-KCl(g)Saturated steam-NaCl(g)AC/GAS/Na2SO4AC/GAS/K2SO4AC/GAS/PbOAC/GAS/ZnO
• Burn clean gas in gas fired boiler1,E-09
350
370
390
410
430
450
470
490
510
530
550
570
590
610
630
650
670
690
710
730
750
770
790
810
830
850
870
890
910
930
950
970
990
1010
1030
1050
1070
1090
1110
1130
1150
1170
1190
Temperature [C]
1
2. 3.
4.
5. 1. Fuel handling 2. Gasifier3 Gas cooling1. 3. Gas cooling 4. Gas filter 5. Gas boiler and
flue gas cleaning
© Metso19 IEA Task 33 Meeting in Piteå19.10.2011
Operational window to clean out corrosivecompounds
• All water walls cooled with boiler feed • High temperature ceramic filterAll water walls cooled with boiler feed water– Avoid risk of corrosion in cooler – Condensate corrosive components on
• High temperature ceramic filter– Filter can tolerate high temperatures – Tar condensation can be avoided
pparticles
– Avoid tar condensation in cooler
© Metso IEA Task 33 Meeting in Piteå 19.10.201120
Benefits of waste gasification • High steam parameters higher efficiency
- Lahti 160 MW fuel => 50 MWe + 90 MW district heatL h i 120 b 40 C li- Lahti 120 bar, 540 C live steam
- Technology can offer even higher electricity efficiency• Lower grade waste as a fuel lower fuel cost
L hti f l H h ld t ( i i t d) I d t i l t d liti d- Lahti fuel : Household waste (origin sorted), Industrial waste, demolition wood, waste wood from industry
- LHV 14 -24 MJ/kg, dry ; Moisture< 30 %, Cl < 0,4 %• Tolerance for fuel quality multiple fuel sourcesTolerance for fuel quality multiple fuel sources• Less corrosion less expensive materials in the boiler
© Metso IEA Task 33 Meeting in Piteå 19.10.201121
“Modern” technology vs. Metso technology
Modern grate firing waste power plant (www jly fi)
Metso technologypower plant (www.jly.fi)
Power Heat Loss
Lahti Case(www.roskatenergiaksi.fi)
Power Heat Loss
25%15%
31%
13%
60% 56%
Metso technology is not limiting steam parameters, it is possible to built a plant with even higher power efficiency than Lahti
• Metso technology: Worlds highest power production efficiency in waste firing
© Metso Date Author Title22
The pilot phase is over
Technology has been available since the 1970’s
“Let’s finally start using it!”Janne Savelainen – Lahti Energia
© Metso IEA Task 33 Meeting in Piteå 19.10.201123